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RE: Are my ears really that sensitive?

The option of raising the mid LP inductor from .4 to .7 mH is interesting, but may end up cutting you off too low- that is nearly an octave's worth - if you have something like 0.1-0.2 mH to add on to the 0.4 that might not be too drastic, but if you like what the simulation shows, go ahead - you already have the parts. I would not worry about the 18ga wire for now, as you say, it is good enough for experimentation.

As for reproducing the MG20 XO in the IIIa, I think that you can start with the top filters and change the 18/12 to 18/6 later on. It is just a wire snip and possibly a cap substitution. In my setup doing anything other than 1st order on the midrange is so disuptive to SQ that I just don't do it at all. The initial experimentation with the free midrange was incredibly instructive as to how good things can sound. I only added the filters because the amp and drivers needed protection from loud bass and in order to do away with the head in a vise problem due to low dispersion of the midrange beyond 6-8 khz.

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